Welding Parameters

    Grettings !

    Im looking for some examples/tips/reading material on Welding parameters for Arc Welding with Robot.

    We mainly use gas mixture of Ar+18%CO2 mixture, We are using Binzel iROB pulse 500 as our power source with their Binzel torches.

    Ive tried doing two T welds on 150A with 5mm sheet metal, robot speed was 30cm/min and voltage 26 V. Wire stickout was at about 10 mm. The welds were not good ( inssuficient penetration).

    Im new at all this so any help/tips/experiments you guys could offer would be greatly appreciated !

    Thank you for the replies, have a great one

    Edited once, last by darth0 (January 23, 2025 at 12:26 PM).

    I was dealing with arc welding long time ago (almost 40 years).

    The gas you are using is also called corgon18 (this gas is very tolerant)
    - How sounded the noise while welding?
    - What's about spatters?
    - What angels you were using?
    - Besides welding speed what's about the wire feed speed?

    Penetration:
    Do you have a picture showing the penetration?

    The idea that time (I was dealing with arc welding) was creating a data base using

    • Material to be welt together
    • Type of joint
    • Thickness
    • Gas

    If this data base would have been available then you would have the answer.

    What is chat gpt saying?
    Have you checked the youtube videas?
    Or just asked Binzel for assistance (I think this would be the best learning curve)?

    Hey MOM ty for the reply !

    The sound was a bit of a PRRR with IEEEEE IEEEE, spatter was Okish i think. Angels were flat on table welding of a T-joint.

    I can take some pictures of the parts i welded and post them for better clearance, havent been able to get them cut in half to inspect the weld.

    We only use the CORGON 18 gas mixture.

    Ill try and ask chat gpt for some help i guess, ive read all the binzel pdfs but they are so poorly written they dont even include what each button does in their pdfs, ill write them a mail and ask for some more detailed instructions/pdfs on the IROB pulse 500

    is there a place for wirespeed in the weld setup or are you just working with amps and volts

    id be inclinded to increase the amps and increase your weldspeed...

    do some tests. Your only welding 3/16 so you dont want it too hot.

    if the weld isnt full then your either travelling too fast or not enough wire. can be a bit of both.

    Actually 30 cm is 11 inches/min. kind of slow. might want to bump that up and adjust your current values as well.

    I have a lot of weld settings where the amps and volts are the same but the travel speed is increased. If your weld speed is too slow the deposited material will build up and you won't get the penetration

    Edited once, last by jarm (February 5, 2025 at 5:28 PM).

    Can someone provide some tips on how to NOT get a Welding Crater at the end of my welds ?

    Link to pictures : https://imgur.com/a/Q7fi4vH,

    Welding parameters:

    I=215A,

    U=28V,

    Wire feed : 11.2 m/min,

    Robot travel speed : 38 cm/min,

    Arc correction length (+0.1) - Not entirely sure what this even does, how it corrects arc length.

    Weld END condition parameters are set at 80% Voltage, Gas postflow 0.5s.

    Torch angle is at 45°-50° with a push angle of 7°.


    I tried to program the robot trajectory so when it reaches the END position of the weld, the robot travels backwards 5mm and starts moving away from the weld ( vertically for about 5 mm).

    Any ideas/concepts and tips on how to remidy this welding mistake would be greatly appreciated!


    Thank you all

    Try to lower delay time on WELD END and make lower parameters on WELD END than WELD


    Make point after weld end with same index as weld end point but add Tool_Offset

    Quote from Deni68

    Try to lower delay time on WELD END and make lower parameters on WELD END than WELD


    Make point after weld end with same index as weld end point but add Tool_Offset

    Hey, thanks for the fast answer !

    currently i dont have any delay timer at the WELD END ( unless its set by GAS POSTFLOW - 0.5s currently).

    Should i Add a Timer on the Move instruction at the end of the Weld or at The move instruction where it moves backwards 5mm ?

    To how much should i lower the END Crater Voltage ? Right now its set at 80% of 28V which would be 22.4 V (28V x 0.8 = 22.4V).

    "Make point after weld end with same index as weld end point but add Tool_Offset"

    Not sure what you meant by this as i have close to zero practical experience about robots and neither does anyone at our company, we dont have any Tool_offset values etc configured or saved in our robot.

    We have a Binzel torch mounted, we use Pliers to cut the wire at about 8mm stickout.

    I dont know the way you are typing parameters, i have function as you see so im writing parameters always before welding.

    You can check schedules on DATA -> WELD PROCEDURE and there are procedures in which you can open schedules.

    When you get DETAIL for schedule there you will have all parameters about weld. (delay time too)

    For making tool offset you can find some posts about that but easly you can go to weld end point and take COORD on TOOL and go with Z+ and make point.

    Im typing my parameters into our Weld source ( Binzel iROB pulse 500). I then call theese parameters with the Macro Inform function.

    I then simply use ARCON at POS where robot should start the weld and ARCOF at where the weld should end ( i added a step so the robot moves backwards 5 mm and uwards 5 mm and then stops welding, hoping this would remedy the Craters at the end of my welds, but the craters are still there).

    I can also try some test by using the Yaskawa robot Arc Set files and Arc end files to "fine tune " the parameters i guess.

    Do you have any reccomendations as to over what distance i should set the "Slope down" function? Would 20 mm be enough ?

    Ive read that setting ARC end crater conditions below 0.3s has no effect as the "system" needs about 0.3s to read and change all the inputs, so it should be set anywhere from 0.3-0.5s as a start value. Would this be ok ?

    Ill upload some pics of our setup and parameters im working with for you in about an hour for clarification.

    jarm Ty for joining the topic of helping me weld :smiling_face: !

    Deni68 Here are some images of my parameters, program pathing and weld results.


    So ive done a couple of more tests and here are the links to Parameters and results:


    Test 1: Using Welding Source to set the welding parameters

    Link to parameters: https://imgur.com/a/welding-parameters-weld-source-GGBp484,

    -----------------------------------------------------------------------------------------------------------------------------------------

    ! Imgur didnt load all images, missing Downslope pictures and end conditions which are :

    Downslope : 80% for 1s , Wire burnout = 0, Gas postflow 0.5s.

    ----------------------------------------------------------------------------------------------------------------------------------------

    Robot Trajectory link: https://imgur.com/a/welding-trajectory-elUebx6,

    Welding Results link : https://imgur.com/a/weld-result-…ameters-12hOiVG,


    I came to the conclusion that using just the weld source parameters i cannot "finetune" the end crater conditions, so maybe using the ASF & AEF would be better / more precise ?


    Test 2: Using ASF & AEF to set parameters

    Link to ASF & AEF parameters : https://imgur.com/a/weld-parameters-asf-aef-fVKbTLy

    Link to Program & Weld results : https://imgur.com/a/aef-program-results-vylCBBJ


    im gonna do another test either today or tomorrow and try and increase the Crater Fill time to 1 - 2 seconds and post the results tommorrow.


    Thank you for your help and inputs everyone!

    its exactly what i do, program robots to weld. don't overthink it.

    i weld on heavier material then you but all my weld settings are based on deposition rates.

    Lets say 4 different weld sizes. i know the deposition rate at a certain wire size and feed rate. i control the heat with voltage and adjust my travel speed for the different weld sizes and run basically a constant current value through all weld settings.

    Those apps are good for a human welder but your using a robot that can apply the process alot faster then any human. i don't know many actual welders that would put that size weld in at 11 inches a minute.

    Edited once, last by jarm (February 11, 2025 at 5:06 PM).

    jarm

    Hey thanks for the reply !

    Im new at this job, having never worked with robots before except in middle school and university, close to 0 experience in mig/mag welding.

    We mostly use 5mm, 10mm, 15mm steel so i started doing tests with theese thickness. One thing i forgot to mention is, we only use 1mm solid core wire and Ar18%C02 (M21) gas mixture.

    Could you explain or provide some reading material about the deposition rate you mention? how would one calculate it for a specific weld ( lets say T weld with 10 mm steel).

    Quote

    i control the heat with voltage and adjust my travel speed for the different weld sizes and run basically a constant current value through all weld settings.

    This is my plan also. We want to set up our welding parameters for 10 mm sheet steel and then "fine tune" them for each welding position and weld type we do, changing only robot speeds and Voltage where needed.

    The welding parameters of Wire feed speed are in European units, so its meter/min, not inches. It would equate to about 39inch/min if my math works.

    But yea my main problem is i have never worked with MIG/MAG welding and im having troubles setting up the parameters to do nice, good looking quality welds. I did a lot of reading on the topic but there are so many parameters and variables that come into the equation its a bit overwhelming.

    You change the speed, and the weld doesnt fill nicely, i up the voltage it causes burnthrough, i lower the Voltage, the weld sticks and i dont get proper penetration....

    Just getting gray hair thinking about it xD

    Quote from jarm

    There is a lot of info on the net. Just google welding deposition rate and jump down the rabbit hole. lol There are even calculators to help.

    I did some reading and im still confused about a lot of stuff.

    I was hoping that some of you more knowledgable and experienced people on this forum would be prepared to help me out ( is that not the point of this forum - to help fellow engineers out with their problems and share knowledge ?)

    Question 1:

    Quote

    i control the heat with voltage and adjust my travel speed for the different weld sizes and run basically a constant current value through all weld settings.

    If you lower the voltage, doesnt that change the transfer mode ( for example from spray to globular) ?

    I can provide an example of a weld we are having trouble filling. Ive calculated the deposition rate needed to fill the weld at 2.8 kg/min or 6.2 lb/min.

    The Weld Volume is 1.9125x10-5 m3

    Now how does this data help me calculate what Travel speed i would need to fill in the Weld properly ?

    And again, I wouldnt be asking for tips and information here if i was able to find it on my own... Ive read a lot of articles,forums etc on this topic but i failed to find the information i would need.

    calculate your deposition rate using wire size and feed rate...it wont be 100% obviously.

    Yes the voltage will determine the transfer type.

    There are charts that give you a rough percentage based on transfer type.

    What is the length of the weld that requires 1.9125x10-5 m3?

    What robot are you using? Are you using a motoman? Do you have a wirefeed setting or do you just have a current setting? Some robots give both options

    you need to calculate the volume of wire needed to do the weld and depending on your feed rate and the length of the weld you can calculate the travel speed.

    Figure out the length of wire needed for the weld divided by your feed rate. That will give you the time needed to do the weld. if it takes 60 secs to feed enough wire to do the weld and the weld is a foot long then your travel speed would be 12 inches a minute.... just an example....but you should get the jist of it. Its all just a rough calculation but it will get you in the ballpark and you can fine tune from there

    Edited 3 times, last by jarm (February 13, 2025 at 3:30 PM).

    jarm hey thanks for the reply!

    The length of the weld is 340mm, Profile of the weld is : Catheti : 15mm, angle between them is 30°.

    We are using a Motoman YR-1-06VXH25-A10 robot with YRC1000 controler. We have a Binzel iROB 500 power source where we set the parameters for welding including wire feed speed. We then "fine tune" the parameters where needed with arcset & ASF etc.

    for the specific weld we are using parameters I=185A, 28.1V, Wire feed is 10 m/min, robot speed is 30 cm/min, Gas mixture is Ar18%CO2 (M21), wire is 1 mm solid core. We cant use weaving because there is not enough space.

    The online calculators i used provide the answer i need 0.6 kg of wire to fill the weld.

    So now i can calculate the mass of the weld ( from volume) and then I divide that number with 0.6kg to get travel speed if i understand correctly ?

    So here are my calculations if you would be so kind as to check them and say where i went wrong? The problem is i found multiple formulas/calculators online and not sure which one to use or if they are correct.

    Weld Volume: Area X length = 56.25mm2 x 340mm = 19 125 mm3.

    Deposition rate : ( I x U x 0.9)/(1000) = (185A x 28.1 V x 0.9)/(1000) = 4,678 kg/min

    Wire melt off /deposition rate(calculator) : =13.1⋅D2⋅S⋅E = 13.1 x 0.785mm2 x 7.860 kg/m3 x0.9 = 3.2 kg/h.

    Edited once, last by darth0 (February 14, 2025 at 7:49 AM).

Advertising from our partners